The Benefits of Steam System Optimisation

That was the conclusion of the Intergovernmental Panel on Climate Change's report earlier this year. A clarion call certainly, but, as the authors suggest, "Net zero CO2 emissions from the industrial sector are challenging but possible." 

Over its 2,000+ pages, the IPCC report scrutinises every aspect of the climate crisis. When it deals with reducing greenhouse gases (GHG) from the overall energy sector, it suggests that this, “requires major transitions, including a substantial reduction in overall fossil fuel use, the deployment of low-emission energy sources, switching to alternative energy carriers, and energy efficiency and conservation.”³ 

Echoing the IPCC's message, the Chief Executive of the Science Based Targets initiative (SBTi), Luiz Amaral pointed out that limiting global warming to 1.5°C requires a peak before 2025, reducing emissions by 43% by 2030, 60% by 2035 and reach net-zero in early 2050. 

It's not going to be easy, but with the right mindset, meaningful progress can be made towards a more sustainable future. 

It's encouraging to see the progress being made by the 2,731 companies with science-based targets, of which we're one. By focusing on the now and refusing to allow the status quo to control the narrative, progress is being made. Companies will have different ways of achieving their goals, but a common theme is efficiency. 

That was one of the key messages from the Biden-Harris administration's Industrial Decarbonization Roadmap, published in September last year. As the country with the second-largest CO2 emissions in the world, any progress in detailing how it aims to tackle this is welcome. Recognising that 30% of US energy-related CO2 emissions originate from industry, it focuses on the way forward for five of the highest CO2-emitting industries: petroleum refining, chemicals, iron and steel, cement, and the food and beverage sectors. 

Of the four key technological pillars identified, it concludes: 

"Energy efficiency is a foundational, crosscutting decarbonization strategy and is the most cost-effective option for GHG emission reductions in the near term.”⁵ 

Not only the American government saw efficiency as part of the blueprint to averting climate disaster. The IEA released their tracking report on Energy Efficiency in the same month, emphasising: 

“Energy efficiency is the single largest measure to avoid energy demand in the Net Zero Emissions by 2050 Scenario, along with the closely related measures of electrification, behavioural change, digitalisation and material efficiency.”⁶ 

You might think that nothing could be more businesslike than increasing efficiency. That it's on every day's agenda. Then why are we constantly being reminded of its importance? 

Widely recognised by many industries as being an essential, enduring part of their processes, steam is a naturally efficient source of thermal energy. That doesn't mean steam systems cannot be improved, but experience and expertise mean we do know how to go about that. 

There are a range of proven, cost-effective measures to improve a steam system. Why these are not universally adopted is down to a combination of factors, many of these not related to monetary obstacles. 

The first, and simplest reason is due to a lack of information and knowledge. Whilst recent high-level reports have pointed to efficiency as a first step towards decarbonisation, steam systems are complex, often unique to a particular industry, or even plant. Knowing where to optimise, how to go about it effectively, and understanding exactly what the benefits will be, require specialist help. 

A range of other factors combines to keep efficiency top of the “yet-to-do” list for many companies. Often a lack of financial resources makes it hard to adopt even measures which will pay for themselves in a short time (especially for small-medium enterprises). The absence of support from top management, uncertainty about new technologies and fear of production disruption, and lack of government incentives coupled with lack of enforcement for government regulations, all add to inaction. 

Beyond general barriers hindering efficiency improvements, steam systems have their own specific set of difficulties to overcome. Traditionally, many companies have focused on boilers, not the entire steam system that includes steam generation (boilers), distribution, recovery systems, and how steam is used. 

Circling back to those energy statistics we covered at the beginning of this article, and the challenge ahead for reaching net zero targets, it is useful to see how generalisations around "efficiency" might actually translate into action. 

None of these measures are awaiting development. All are technically possible and, in most cases, cost-effective over a relatively short period of time. And, most importantly, they'll reap tangible benefits whilst the other, newer technologies are still in the early stages of their evolution. 

Since the UNIDO report was published, the potential for optimising steam systems has advanced too. Now, with digital transformation rapidly being adopted, our knowledge of exactly where optimisation will be most effective is far greater. It’s something the IPCC highlighted in their report this year: